Dark colored easy-to-clean enamel

ABSTRACT

A composition that upon firing, forms a low-temperature clean enamel layer is disclosed. The composition can be applied to a metal substrate to provide a low-temperature cleaning, durable coating for cooking surfaces. Also disclosed are methods of forming enamel layers and corresponding coated substrates. Various ground coats and related methods are also described. Furthermore, various multilayer coatings and structures are disclosed that include an enamel layer and a ground coat layer.

STATEMENT OF RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.12/768,213 filed 27 Apr. 2010, which is incorporated by reference hereinfor all purposes.

FIELD OF THE INVENTION

The present invention provides enamel compositions and ground coatcompositions. More particularly, the present invention providescompositions for use in forming an acid resistant and chip resistantenamel cover coating from which baked-on foods can be removed withoutthe need for pyrolysis or highly alkaline cleaners. Also provided aremethods for forming the enamel coating, enamel coated substrates, groundcoat, and multilayer coated substrates.

BACKGROUND OF THE INVENTION

An oven can be one of the most difficult kitchen appliances to clean.Food that splatters onto the interior surfaces of an oven during cookingusually becomes baked-on, making the removal thereof particularlydifficult. If the oven is not frequently cleaned, the amount of baked-onfood can build up rapidly, thereby increasing the cleaning difficulty.

Coatings used for the interiors of ovens are primarily one of threetypes: (1) self-cleaning pyrolytic ground coats, (2) non-self-cleaningground coats, and (3) catalytic continuous clean enamels.

The first type of coatings, i.e. self-cleaning pyrolytic ground coats,enable food residue to be reduced to ash by exposure to temperaturesbetween about 850 and 1000° F. (455 and 538° C.). However, there areseveral concerns associated with heating oven coatings to suchtemperatures. First, high temperatures are required, necessitating extrainsulation around the oven chamber and safety interlocks for ovenoperation. Second, producing such high temperatures requires relativelylarge amounts of energy consumption. Third, depending upon the materialsexposed to such high temperatures, concerns exist as to the possiblerelease of toxic fumes. Fourth, the cleaning cycle used in associationwith these coatings takes up to three hours to complete and potentiallyreduces the overall service life of the oven. Further, in order towithstand multiple cleaning cycles, such enamel coatings generallycontain hard, chemically-resistant frits that, without high-temperatureexposure, have inherently poor release properties, thereby compoundingthe difficulty in removing baked-on residues.

The second type of coating, i.e. non-self-cleaning ground coats,requires significant cleaning efforts by the consumer and/or harshalkaline saponifying cleaners that have a pH of approximately 14. Aswill be appreciated, significant safety concerns exist when using,handing, and storing such hazardous and often toxic cleaners. Inaddition, producing various oven models each with potentially differentinterior coatings can increase manufacturing complexity and thus costs.In order to provide a lower cost appliance, Original EquipmentManufacturers (OEMs) generally use the same pyrolytic enamel as used inself-cleaning ovens, but do not equip the oven with a self-clean cycle.Thus, although satisfactory, many ovens such as those lacking aself-cleaning cycle, utilize coatings that are not optimally designedfor the oven.

The third type of coating, i.e. catalytic continuous clean enamels, fireout with a porous microstructure, enabling the reduction of food residueto ash at normal cooking temperatures. Although satisfactory in manyregards, these coatings have largely fallen out of use in North Americabut are still in use in other markets.

The patent literature has described enamel cover coatings. U.S. Pat. No.7,005,396 describes enamel formulas that include mixtures of lowsoftening point alkali aluminophosphate frit with a high softening pointzirconia phosphate frit. The soft frit fluxes the hard frit, creatingworkability within typical oven enamel firing conditions of 1520 to1600° F. (827 to 871° C.). The fired coating sheds baked-on foodstuffsupon exposure to a moist environment. The soil release mechanism ishypothesized to be due to relatively weakly bonded surface absorbedwater rather than the significantly stronger bonds otherwise occurringon conventional enamels. When applied to an oven cavity, this surfacecreates a fourth option for soil removal through relatively briefexposure to water or steam at much lower temperatures than used with thepyrolytic enamels and without the use of harsh alkaline cleaners.

However, the glasses discussed in U.S. Pat. No. 7,005,396 have certaincharacteristics that preclude their use in oven applications usingground coats or that render them difficult to apply with dryelectrostatic methods to oven surfaces. The thermal expansion of theglasses is too high relative to ground coats typically used in ovens.This difference in thermal expansion characteristics would lead tocracking or other distortions in an oven coating using such glasses. Inaddition, the glass temperature of the glasses is below 750° F. (400°C.). On hidden bake ovens in which an oven floor covers the heatingelement, the floor can exceed these temperatures. Foods baked-on abovethe glass temperature would then not necessarily release upon exposureto moisture. As for their application characteristics, a soft and hardfrit with mill-added raw materials described in that patent would tendto segregate on recirculation through an automatic spray booth and thusthis characteristic detracts from application of the glass mixture viaspraying.

Accordingly, there exists a need for a composition that can be appliedto the interior surfaces of oven cavities and other articles from whichbaked-on foods can be easily removed without the need for pyrolysis orhighly alkaline cleaners.

SUMMARY OF THE INVENTION

The difficulties and drawbacks associated with previously known systemsare addressed in the present compositions, methods, and coatedsubstrates involving enamel cover coatings and ground coats that enablebaked-on foods to be easily removed.

The compositions of the invention may be produced in a wide range ofcolors, however charred food soils will stain lighter colored coating.To reduce the appearance of stains, the color of the porcelain enamelshould be relatively dark. The Hunter L color value should be below 30,preferably below 25, more preferably below 20 and still more preferablybelow 15.

The inventors have discovered that, while nickel can be effectively usedto adjust color, the removal of nickel eliminates problems of metalizingaround the edges of a substrate coated with the enamel composition ofthe invention.

Mixed metal oxides such as cobalt oxide, chrome oxide, copper oxide andmanganese oxide are added to the enamels of the invention without theuse of nickel oxide to achieve the desired color, neutral grey, withHunter L<30. Cobalt and chrome produce a darker yet more neutral color.In particular, the enamel compositions of the invention include lessthan 2 wt % Ni, preferably less than 1.5% Ni, more preferably less than1 wt % Ni, still more preferably less than 0.5 wt % Ni, even morepreferably less than 0.25 wt % Ni and still more preferably less than0.1 wt % Ni. Most preferably, the compositions of the invention arenickel free.

An embodiment of the invention is a process for obtaining a firedcoating having a Hunter L color value less than 30 comprising: (a)applying to a substrate a composition comprising: (i) a glass componentincluding: from about 7% to about 25% of at least one R₂O; from about 0%to about 15% of at least one RO; from about 5% to about 20% of at leastone MO₂; from about 8% to about 25% of Al₂O₃; from about 3% to about 25%of SiO₂; from about 15% to about 40% of P₂O₅; and (ii) an effectiveamount of an additive; wherein R₂O is an alkali oxide, RO is an alkalineearth oxide, and MO, MO₂ and M₂O₃ are transition metal oxides.

Generally, the present invention provides a composition adapted forforming an enamel coating. The composition prior to firing, comprises:(i) a glass component including from about 10.0% to about 20.0% of atleast one R₂O, from about 2.7% to about 3.3% of at least one RO, fromabout 0.6% to about 2.8% of at least one MO, from about 15.1% to about17.6% of at least one MO₂, from about 0.1% to about 6.3% of at least oneM₂O₃, from about 19.3% to about 20.7% of Al₂O₃, from about 10.8% toabout 11.8% of SiO₂, and from about 29.2% to about 31.3% of P₂O₅, and(ii) an effective amount of an additive. R₂O is an alkali oxide, RO isan alkaline earth oxide, and MO, MO₂ and M₂O₃ are transition metaloxides. Also provided are methods of forming enamel coatings onsubstrates by use of these compositions. And, the present inventionadditionally provides various enamel coated substrates.

More specifically, and in one aspect, the present invention provides acomposition adapted for forming an enamel coating. The composition priorto firing, comprises (i) a glass component that includes from about 7.1%to about 7.9% Na₂O, from about 7.0% to about 7.7% K₂O, from about 0.6%to about 1.0% ZnO, from about 2.7% to about 3.3% BaO, from about 19.3%to about 20.7% Al₂O₃, from about 10.8% to about 11.8% SiO₂, from about0.7% to about 1.2% TiO₂, from about 14.4% to about 15.6% ZrO₂, fromabout 29.2% to about 31.3% P₂O₅, and from about 0.1% to about 5.2%Co₂O₃, and (ii) an effective amount of at least one additive selectedfrom the group consisting of fluorine and NO₂.

Specifically and in another aspect, the present invention provides amethod for forming an enamel coating on a substrate. The methodcomprises providing a substrate for receiving the coating. The methodalso comprises providing a composition that includes (i) a glasscomponent and (ii) an effective amount of at least one additive selectedfrom the group consisting of fluorine and NO₂. The glass componentincludes from about 7.1% to about 7.9% Na₂O, from about 7.0% to about7.7% K₂O, from about 0.6% to about 1.0% ZnO, from about 2.7% to about3.3% BaO, from about 19.3% to about 20.7% Al₂O₃, from about 10.8% toabout 11.8% SiO₂, from about 0.7% to about 1.2% TiO₂, from about 14.4%to about 15.6% ZrO₂, from about 29.20% to about 31.3% P₂O₅, and fromabout 0.1% to about 5.2% Co₂O₃. The method also comprises depositing alayer of the composition on the substrate. And, the method additionallycomprises firing the layer to thereby form an enamel coating on thesubstrate.

Specifically and in yet another aspect, the present invention providesan enamel coated substrate. The enamel coating has a composition priorto firing that comprises (i) a glass component and (ii) an effectiveamount of at least one additive selected from the group consisting offluorine and NO₂. The glass component includes from about 7.1% to about7.9% Na₂O, from about 7.0% to about 7.7% K₂O, from about 0.6% to about1.0% ZnO, from about 2.7% to about 3.3% BaO, from about 19.3% to about20.7% Al₂O₃, from about 10.8% to about 11.8% SiO₂, from about 0.7% toabout 1.2% TiO₂, from about 14.4% to about 15.6% ZrO₂, from about 29.2%to about 31.3% P₂O₅, and from about 0.1% to about 5.2% Co₂O₃.

Generally, the present invention also provides a composition adapted forforming a ground coat. The composition prior to firing, comprises: fromabout 14.4% to about 18.4% of at least one R₂O, from about 8.5% to about11.7% of at least one RO, from about 2.5% to about 5.3% of at least oneMO, from about 4.0% to about 9.2% of at least one MO₂, from about 0.4%to about 1.4% of at least one M₂O₃, from about 16.0% to about 17.2% ofB₂O₃, from about 2.0% to about 5.0% of Al₂O₃, from about 41.8% to about46.2% of SiO₂, and an effective amount of at least one additive. Inaddition, the present invention provides various methods of formingground coats by use of these compositions, and the resulting groundcoated substrates.

More specifically and in still a further aspect, the present inventionprovides a composition adapted for forming a ground coat. Thecomposition prior to firing, comprises from about 2.5% to about 3.6%Li₂O, from about 11.0% to about 12.7% Na₂O, from about 0.9% to about2.1% K₂O, from about 5.4% to about 6.8% CaO, from about 3.1% to about4.9% BaO, from about 16.0% to about 17.2% B₂O₃, from about 2.0% to about5.0% Al₂O₃, from about 41.8% to about 46.2% SiO₂, from about 0% to about1.6% TiO₂, from about 3.0% to about 6.3% ZrO₂, from about 2.2% to about3.2% NiO, from about 0.3% to about 1.2% CuO, from about 0.05% to about0.9% Fe₂O₃, from about 0.4% to about 1.4% Co₂O₃, and from about 1.0% toabout 1.3% MnO₂. The composition also comprises an effective amount ofat least one additive selected from the group consisting of fluorine andNO₂.

Specifically and in another aspect, the present invention provides amethod of forming a ground coat on a substrate. The method comprisesproviding a substrate, and providing a composition comprising (i) aneffective amount of at least one additive selected from the groupconsisting of fluorine and NO₂, and (ii) a ground coat formulation. Theground coat formulation includes from about 2.5% to about 3.6% Li₂O,from about 11.0% to about 12.7% Na₂O, from about 0.9% to about 2.1% K₂O,from about 5.4% to about 6.8% CaO, from about 3.1% to about 4.9% BaO,from about 16.0% to about 17.2% B₂O₃, from about 2.0% to about 5.0%Al₂O₃, from about 41.8% to about 46.2% SiO₂, from about 0% to about 1.6%TiO₂, from about 3.0% to about 6.3% ZrO₂, from about 2.2% to about 3.2%NiO, from about 0.3% to about 1.2% CuO, from about 0.05% to about 0.9%Fe₂O₃, from about 0.4% to about 1.4% Co₂O₃, and from about 1.0% to about1.3% MnO₂. The method comprises depositing a layer of the composition onthe substrate, and firing the layer to thereby form a ground coat on thesubstrate.

Specifically and in still another aspect, the present invention providesa ground coated substrate. The ground coat has a composition prior tofiring that comprises from about 2.5% to about 3.6% Li₂O, from about11.0% to about 12.7% Na₂O, from about 0.9% to about 2.1% K₂O, from about5.4% to about 6.8% CaO, from about 3.1% to about 4.9% BaO, from about16.0% to about 17.2% B₂O₃, from about 2.0% to about 5.0% Al₂O₃, fromabout 41.8% to about 46.2% SiO₂, from about 0% to about 1.6% TiO₂, fromabout 3.0% to about 6.3% ZrO₂, from about 2.2% to about 3.2% NiO, fromabout 0.3% to about 1.2% CuO, from about 0.05% to about 0.9% Fe₂O₃, fromabout 0.4% to about 1.4% Co₂O₃, from about 1.0% to about 1.3% MnO₂, andan effective amount of at least one additive selected from the groupconsisting of fluorine and NO₂.

Specifically and in yet another aspect, the present invention alsoprovides a coated substrate including a ground coat disposed on thesubstrate and an enamel coating disposed on the ground coat. The groundcoat has a composition prior to firing that comprises from about 2.5% toabout 3.6% Li₂O, from about 11.0% to about 12.7% Na₂O, from about 0.9%to about 2.1% K₂O, from about 5.4% to about 6.8% CaO, from about 3.1% toabout 4.9% BaO, from about 16.0% to about 17.2% B₂O₃, from about 2.0% toabout 5.0% Al₂O₃, from about 41.8% to about 46.2% SiO₂, from about 0% toabout 1.6% TiO₂, from about 3.0% to about 6.3% ZrO₂, from about 2.2% toabout 3.2% NiO, from about 0.3% to about 1.2% CuO, from about 0.05% toabout 0.9% Fe₂O₃, from about 0.4% to about 1.4% Co₂O₃, from about 1.0%to about 1.3% MnO₂, and an effective amount of at least one additiveselected from the group consisting of fluorine and NO₂. The enamelcoating has a composition prior to firing that comprises (i) a glasscomponent and (ii) an effective amount of at least one additive selectedfrom the group consisting of fluorine and NO₂, wherein the glasscomponent includes: from about 7.1% to about 7.9% Na₂O, from about 7.0%to about 7.7% K₂O, from about 0.6% to about 1.0% ZnO, from about 2.7% toabout 3.3% BaO, from about 19.3% to about 20.7% Al₂O₃, from about 10.8%to about 11.8% SiO₂, from about 0.7% to about 1.2% TiO₂, from about14.4% to about 15.6% ZrO₂, from about 29.2% to about 31.3% P₂O₅, andfrom about 0.1% to about 5.2% Co₂O₃.

In a further aspect, the invention provides a composition adapted forforming an enamel coating, the enamel composition prior to firing,comprising: (i) a glass component including: from about 7% to about 25%,preferably about 10 to about 20%, more preferably about 12% to about 19%of at least one R₂O; from about 0% to about 15%, preferably from about3% to about 12%, more preferably from about 5% to about 11% of at leastone RO; from about 5% to about 20%, preferably from about 8 to about18%, more preferably from about 10% to about 17% of at least one MO₂;from about 8% to about 25%, preferably from about 10% to about 20%, morepreferably from about 12% to about 19% of Al₂O₃; from about 3% to about25%, preferably from about 5% to about 20%, more preferably from about7% to about 18% of SiO₂; from about 15% to about 40%, preferably fromabout 20% to about 35%, more preferably 22% to about 32% of P₂O₅; and(ii) an effective amount of an additive; wherein R₂O is an alkali oxide,RO is an alkaline earth oxide, and MO, MO₂ and M₂O₃ are transition metaloxides.

In still a further aspect, the invention provides a method of forming anenamel coating on a substrate, the method comprising: providing asubstrate; providing a composition comprising (i) a glass component and(ii) an effective amount of an additive, wherein the glass componentincludes from about from about 7% to about 25%, preferably about 10 toabout 20%, more preferably about 12% to about 19% of at least one R₂O;from about 0% to about 15%, preferably from about 3% to about 12%, morepreferably from about 5% to about 11% of at least one RO; from about 5%to about 20%, preferably from about 8 to about 18%, more preferably fromabout 10% to about 17% of at least one MO₂; from about 8% to about 25%,preferably from about 10% to about 20%, more preferably from about 12%to about 19% of Al₂O₃; from about 3% to about 25%, preferably from about5% to about 20%, more preferably from about 7% to about 18% of SiO₂;from about 15% to about 40%, preferably from about 20% to about 35%,more preferably 22% to about 32% of P₂O₅; and (ii) an effective amountof an additive; wherein R₂O is an alkali oxide, RO is an alkaline earthoxide, and MO, MO₂ and M₂O₃ are transition metal oxides; depositing alayer of the composition on the substrate; and firing the layer tothereby form an enamel coating on the substrate.

In yet another aspect, the invention provides an enamel coatedsubstrate, the enamel coating having a composition prior to firing thatcomprises: (i) a glass component and (ii) an effective amount of atleast one additive, wherein the glass component includes from about 7%to about 25% of at least one R₂O; from about 0% to about 15% of at leastone RO; from about 5% to about 20% of at least one MO₂; from about 8% toabout 25% of Al₂O₃; from about 3% to about 25% of SiO₂; from about 15%to about 40% of P₂O₅; wherein R₂O is an alkali oxide, RO is an alkalineearth oxide, and MO, MO₂ and M₂O₃ are transition metal oxides.

As will be realized, the invention is capable of other and differentembodiments and its several details are capable of modifications invarious respects, all without departing from the invention. Accordingly,the description is to be regarded as illustrative and not restrictive.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The present invention provides compositions for use in forming an enamelcover coating from which baked-on foods can be removed without the needfor pyrolysis or highly alkaline cleaners. The enamel cover coatingproduced using the compositions according to the invention exhibits nochipping or other surface defects after cleaning and removal of baked-onfoods. Coated substrates according to the invention exhibit excellentfood removal characteristics and do not require pyrolysis or use ofcaustic cleaners. The present invention also provides compositions foruse in forming ground coatings or “ground coats” on substrates, andwhich coatings are well suited for receiving the enamel cover coatsdescribed herein.

Enamel Compositions

The enamel compositions of the present invention are preferably providedin the form of a dry powder. This promotes storage and enables thecomposition to be applied to substrates by well known powder coatingprocesses. However, the compositions can also be provided and applied ina wet state such as a water-based slurry.

The enamel compositions of the invention include a glass component andan effective amount of one or more additives such as fluorine and/orNO₂. The glass component includes one or more oxides selected from thegroup consisting of P₂O₅, Al₂O₃, ZrO₂, SiO₂, Na₂O, K₂O, BaO, TiO₂, ZnO,Co₂O₃, NiO, Cr₂O₃, MnO₂, CuO, and combinations thereof. The compositionsmay also include one or more additional components such as but notlimited to Li₂O, Rb₂O, Cs₂O, MgO, CaO, SrO, ZnO, CeO₂, LaO₂, B₂O₃, FeO,Fe₂O₃, and Fe₃O₄.

The glass component of the enamel compositions preferably comprises acombination of one or more alkali oxides represented as R₂O, one or morealkaline earth oxides represented as RO, and one or more varioustransition metal oxides represented herein as MO, MO₂, and M₂O₃.

The formula R₂O represents alkali oxides, preferably selected from thegroup consisting of Li₂O, Na₂O, and K₂O. The formula RO representsalkaline earth oxides, preferably selected from the group consisting ofMgO, CaO, SrO, and BaO.

The formulas MO, MO₂, and M₂O₃ represent transition metal oxides. MOincludes ZnO, NiO, and CuO for example. MO₂ includes TiO₂ and ZrO₂ forexample. And, M₂O₃ includes Co₂O₃ and Cr₂O₃ for example. It will beunderstood that M can be any transition metal as known in the art.

Preferably, the glass component of the enamel compositions comprises,prior to firing, from about 10.0% to about 20.0% and more preferablyfrom about 14.1% to about 15.6% of one or more R₂O; from about 2.7% toabout 3.3% of one or more RO; from about 0.6% to about 2.8% of one ormore MO; from about 15.1% to about 17.6% of one or more MO₂; from about0.1% to about 6.3% of one or more M₂O₃; from about 19.3% to about 20.7%of Al₂O₃; from about 10.8% to about 11.8% of SiO₂; and from about 29.2%to about 31.3% of P₂O₅.

Preferably and more specifically, the enamel compositions prior tofiring, comprise (i) a glass component that includes from about 7.1% toabout 7.9% Na₂O, from about 7.0% to about 7.7% K₂O, from about 0.6% toabout 1.0% ZnO, from about 2.7% to about 3.3% BaO, from about 19.3% toabout 20.7% Al₂O₃, from about 10.8% to about 11.8% SiO₂, from about 0.7%to about 1.2% TiO₂, from about 14.4% to about 15.6% ZrO₂, from about29.2% to about 31.3% P₂O₅, and from about 0.1% to about 5.2% Co₂O₃, and(ii) an effective amount of at least one additive. The term “about” asused herein includes amounts or proportions of the noted component,agent, element or the like that are substantially the same as the notedamount. For example, the term “about” includes values that result whenrounding (up or down) a noted weight percent to a value having a shorterdecimal such as from a weight percent expressed in hundredths of apercent to the nearest tenth of a percent.

Typical, preferred and most preferred ranges for components in theglassy portion of the compositions are set forth below in Table 1 asfollows (all values are in weight percent unless indicated otherwise).

TABLE 1 Glass Component Formulation Ranges Component Most PreferredPreferred Typical Na₂O 7.32-7.72 7.2-7.8 7.1-7.9 K₂O 7.15-7.54 7.1-7.67.0-7.7 ZnO 0.77-0.83 0.7-0.9 0.6-1.0 BaO 2.92-3.12 2.8-3.2 2.7-3.3Al₂O₃ 19.50-20.45 19.4-20.5 19.3-20.7 SiO₂ 11.00-11.63 10.9-11.710.8-11.8 TiO₂ 0.90-1.00 0.8-1.1 0.7-1.2 ZrO₂ 14.60-15.41 14.5-15.514.4-15.6 P₂O₅ 29.50-31.25 29.4-31.3 29.2-31.4 NiO   0-0.93   0-1.0  0-1.1 CuO   0-0.51   0-0.6   0-0.7 Co₂O₃ 0.34-4.90 0.2-5.0 0.1-5.2MnO₂   0-0.59   0-0.7   0-0.8 Cr₂O₃   0-0.90   0-1.0   0-1.1

The present invention provides several preferred compositions set forthbelow in Table 2. These preferred compositions are designated aspreferred compositions A, B, C, D, E, and F.

TABLE 2 Glass Component Preferred Compositions Preferred PreferredPreferred Component Composition A Composition B Composition C Na₂O 7.627.61 7.70 K₂O 7.44 7.44 7.52 ZnO 0.81 0.79 0.80 BaO 3.06 3.06 3.10 Al₂O₃20.25 20.21 20.43 SiO₂ 11.50 11.49 11.61 TiO₂ 0.96 0.97 0.98 ZrO₂ 15.2115.22 15.39 P₂O₅ 30.81 30.78 31.13 NiO 0.91 — — CuO 0.49 — — Co₂O₃ 0.361.55 0.46 M_(n)O₂ 0.57 — — Cr₂O₃ — 0.88 0.44 Preferred PreferredPreferred Component Composition D Composition E Composition F Na₂O 7.357.39 7.73 K₂O 7.17 7.21 7.55 ZnO 0.78 0.78 0.80 BaO 2.95 2.97 3.11 Al₂O₃19.52 19.62 20.52 SiO₂ 11.09 11.15 11.66 TiO₂ 0.93 0.93 0.98 ZrO₂ 14.6614.77 15.46 P₂O₅ 29.70 29.85 31.27 NiO 0.88 0.48 — CuO 0.47 — — Co₂O₃0.35 4.85 0.89 M_(n)O₂ 0.55 — — Cr₂O₃ — — —

In addition to the components set forth in Tables 1 and 2, it is alsopreferred to include an additive such as fluorine in an amount typicallyfrom about 0.78% to about 3.00%, preferably from about 0.88% to about2.6%, and most preferably from about 0.91% to about 2.5% of the glasscomponent. And, it is also preferred to include another additive such asNO₂ in an amount of typically from about 1.50% to about 4.71%,preferably from about 2.00% to about 4.61%, and most preferably fromabout 2.40% to about 4.56% of the glass component. These formulationranges for the noted additives are set forth below in Table 3.Typically, after firing, about one-half of the fluorine remains in theresulting layer. Typically, all of the nitrogen dioxide is released ordecomposed during firing.

TABLE 3 Additive Component Formulation Ranges Component Most PreferredPreferred Typical F 0.91-2.5  0.88-2.6  0.78-3.0  NO₂ 2.40-4.562.00-4.61 1.50-4.71

In alternate embodiments of the invention, Preferred compositions G, Hand J are provided.

TABLE 4 Formulation G. Most Preferred Preferred Typical Component RangeG Range G Range G Na₂O 14.01-14.53 13.69-14.61 13.4-14.8 Al₂O₃12.95-13.45 12.72-13.59 12.6-13.8 SiO₂ 18.65-19.35 18.42-19.66 18.2-19.9P₂O₅ 23.11-23.79 22.87-24.07 22.4-24.2 SO3 0.01-0.25 0.01-0.50 0.01-0.8 K₂O 6.27-6.93 6.02-7.15 5.7-7.4 CaO 0.48-0.91 0.37-1.03  0.2-1.20 TiO₂3.58-4.01 3.37-4.23 3.2-4.5 Cr₂O₃ 0.64-0.98 0.55-1.09 0.4-1.3 MnO0.05-0.39 0.01-0.54 0.01-0.70 Fe₂O₃ 1.48-1.94 1.25-2.12 1.1-2.3 Co₃O₄0.01-0.15 0.01-0.25 0.01-0.4  NiO 0.05-0.35 0.01-0.51 0.01-0.7  CuO0.07-0.20 0.01-0.25 0.01-0.3  SrO 0.01-0.10 0.01-0.20 0.01-0.3  Y₂O₃0.03-0.15 0.01-0.21 0.01-0.4  ZrO₂ 11.10-11.59  9.87-11.82  9.5-12.0 BaO2.01-2.59 1.87-2.77 1.6-2.9 F 1.27-1.76 1.14-1.85 0.8-2.0

TABLE 5 Formulation H. Most Preferred Preferred Typical Component RangeH Range H Range H Na₂O 12.49-13.31 12.33-13.55 12.1-13.7 MgO 0.01-0.100.01-0.20 0.01-0.3  SiO₂ 57.43-58.29 57.17-58.37 56.8-58.7 P₂O₅0.05-0.20 0.01-0.25 0.01-0.4  K₂O 4.44-4.93 4.29-5.11 4.1-5.2 CaO2.61-2.99 2.37-3.20 2.1-3.4 TiO₂ 3.02-3.47 2.88-3.59 2.7-3.7 Cr₂O₃0.39-0.82 0.30-0.95 0.2-1.0 MnO 4.12-4.71 3.91-4.92 3.6-5.0 Fe₂O₃4.04-4.67 3.87-4.77 3.7-4.9 Co₃O₄ 1.14-1.63 0.95-1.75 0.8-1.9 NiO0.05-0.15 0.02-0.27 0.01-0.4  CuO 1.44-1.95 1.25-2.08 1.1-2.3 SrO0.01-0.10 0.01-0.20 0.01-0.3  ZrO₂ 0.49-0.88 0.37-0.97 0.2-1.1 MoO₃0.23-0.77 0.15-0.87 0.1-1.0 Sb₂O₃ 0.62-0.97 0.55-1.16 0.4-1.4 BaO1.98-2.37 1.62-2.55 1.5-2.7 F 0.95-1.29 0.82-1.44 0.6-1.7

TABLE 6 Formulation J. Most Preferred Preferred Typical Component RangeJ Range J Range J Na₂O 12.24-12.89 11.94-13.14 11.73-13.31 MgO 0.02-0.150.01-0.20 0.01-0.32 Al₂O₃ 17.29-17.91 16.75-18.12 16.47-18.39 SiO₂18.57-19.37 18.12-19.66 17.77-20.04 P₂O₅ 20.58-21.22 20.45-21.3920.32-21.48 SO3 0.01-0.15 0.01-0.27 0.01-0.40 K₂O 5.26-5.69 4.92-5.814.70-6.08 CaO 0.48-0.91 0.35-0.98 0.27-1.05 TiO₂ 4.21-4.63 3.97-4.893.51-5.14 Cr₂O₃ 2.42-2.79 2.29-2.97 2.05-3.22 MnO 0.21-0.51 0.10-0.750.01-0.98 Fe₂O₃ 0.82-1.41 0.69-1.58 0.55-1.75 Co₃O₄ 0.01-0.15 0.01-0.270.01-0.41 NiO 0.05-0.27 0.01-0.35 0.01-0.48 CuO 1.37-1.88 1.25-2.021.11-2.35 SrO 0.01-0.11 0.01-0.22 0.01-0.31 Y₂O₃ 0.01-0.15 0.01-0.210.01-0.32 ZrO₂ 9.15-9.58 8.85-9.72  8.61-10.00 BaO 1.51-1.99 1.40-2.271.32-2.46 F 1.11-1.64 0.85-1.62 0.75-1.88

TABLE 7 Formulation K. Most Preferred Preferred Typical Component RangeK Range K Range K P₂O₅ 27.57-27.98 27.39-28.18 27.2-28.4 Al₂O₃20.97-21.39 20.75-21.59 20.6-21.8 R₂O 15.08-15.61 14.91-15.78 14.8-16.0B₂O₃ 0.21-0.73 0.12-0.91 0.01-1.00 RO + ZnO 3.47-4.01 3.21-4.32 3.0-4.6TiO₂ + ZrO₂ 15.44-15.92 15.17-16.21 15.0-16.5 SiO₂ 12.19-12.9111.92-13.14 11.7-13.4

TABLE 8 Formulation L. Most Preferred Component Range L Preferred RangeL Typical Range L P₂O₅ 26.87-27.42 26.69-27.71 26.4-28.1 Al₂O₃20.27-20.89 20.02-21.12 19.8-21.4 R₂O 17.79-18.38 17.42-18.51 17.0-18.8B₂O₃ 1.89-2.38 1.61-2.77 1.4-2.9 RO + ZnO 3.17-3.84 3.01-4.12 2.8-4.3TiO₂ + ZrO₂ 13.02-13.65 12.77-13.84 12.5-14.0 SiO₂ 11.38-11.8911.15-12.29 10.9-12.6

TABLE 9 Formulation M. Most Preferred Component Range M Preferred RangeM Typical Range M P₂O₅ 19.77-20.42 19.51-20.68 19.3-20.9 Al₂O₃14.92-15.69 14.71-15.93 14.2-16.2 R₂O 18.37-19.21 18.22-19.55 17.9-19.8B₂O₃ 5.47-6.18 5.28-6.47 5.1-6.8 RO + ZnO 3.07-3.34 2.88-3.68 2.6-3.8TiO₂ + ZrO₂ 11.74-12.33 11.52-12.81 11.2-13.1 SiO₂ 19.50-20.1211.15-12.29 10.9-12.6

The glass frits comprising the glass component of the compositionsaccording to the invention are preferably milled prior to application.Any of the conventional milling techniques can be employed. Millingfineness is not critical, but a fineness of about 2 grams being retainedfrom a 50 gram sample using a 200 mesh sieve is presently consideredoptimal. Other particle size distributions may also be utilized. Aftermilling, it may be desired to subject the milled composition to a postheat treatment such as exposure to temperatures of about 200° F. (93°C.) for about 18 hours. More broadly, the heat treatment may beundertaken after firing, and may be carried out at 70° F. to 500° F.(25° C. to 260° C.) for 1 to 50 hours, preferably 2 to 25 hours.

It will be appreciated that the compositions according to the inventioncan further comprise up to about 20% by weight of one or more milladditions. Suitable mill additions include, for example, clay,bentonite, magnesium carbonate, potassium nitrate, sodium aluminate,boric acid, and pigments. Inorganic materials, such as zirconia,alumina, alumina metaphosphate, spodumene, and feldspar, can also beadded to the composition in order to modify the texture and/or to adjustthe roughness of the fired enamel.

The compositions according to the invention are intended for use as acover coating. The compositions can be applied like any of the knowncover coat enamels for use on sheet steel. For example, the compositionscan be applied directly onto pickled, nickel-coated steel. Thecompositions can be applied onto aluminum substrates. The compositionscan be applied over fired enamel ground coated substrates using knowntwo-coat/two-fire processes. And, the compositions can be applied overunfired ground coats using any of the known two-coat/one-fire processes(e.g., wet/wet, wet/dry, and dry/dry).

Ground Coat Compositions

The present invention also provides various ground coat compositions.These ground coat compositions generally comprise a glassy component andan additive component. These ground coat compositions have beendiscovered to be particularly well suited for use with the enamelcompositions described herein. Moreover, it is also contemplated thatthe various ground coat compositions can be used in conjunction with oneor more other top coat or cover coat formulations.

The glass component of the ground coat compositions preferably comprisesa combination of one or more alkali oxides represented as R₂O, one ormore alkaline earth oxides represented as RO, and one or more varioustransition metal oxides represented herein as MO, MO₂, and M₂O₃.

The formula R₂O represents alkali oxides, preferably selected from thegroup consisting of Li₂O, Na₂O, and K₂O. The formula RO representsalkaline earth oxides, preferably selected from the group consisting ofMgO, CaO, SrO, and BaO.

The formulas MO, MO₂, and M₂O₃ represent transition metal oxides. MOincludes NiO, CuO, and Fe₂O₃ for example. MO₂ includes TiO₂, ZrO₂, andMnO₂ for example. And, M₂O₃ includes Co₂O₃ for example. It will beappreciated that M can be any transition metal as known in the art.

Preferably, the glass component of the ground coat compositionscomprises, prior to firing, from about 14.4% to about 18.4% of one ormore R₂O; from about 8.5% to about 11.7% of one or more RO; from about2.5% to about 5.3% of one or more MO; from about 4.0% to about 9.2% ofone or more MO₂; from about 0.4% to about 1.4% of one or more M₂O₃; fromabout 16.0% to about 17.2% of B₂O₂; from about 2.0% to about 5.0% ofAl₂O₃; and from about 41.8% to about 46.2% of SiO₂.

Table 4 set forth below lists various preferred ground coat formulationsalong with corresponding typical, preferred, and most preferredconcentration ranges for their constituents. Table 5 presents severalpreferred ground coat compositions, designated herein as compositions V,W, X, Y, and Z.

In addition to the components set forth in Tables 4 and 5, it is alsopreferred to include an additive such as fluorine in an amount of fromabout 6.7% to about 9.0%, preferably from about 6.9% to about 8.8%, andmost preferably from about 7.1% to about 8.6%. And, it is preferred touse another additive such as NO₂ in an amount typically from about 2.3%to about 3.3%, preferably from about 2.5% to about 3.1%, and mostpreferably from about 2.7% to about 2.9%. These formulation ranges arenoted in Table 12.

TABLE 10 Ground Coat Formulation Ranges Component Most PreferredPreferred Typical Li₂O 2.9-3.2 2.7-3.4 2.5-3.6 Na₂O 11.4-12.3 11.2-12.511.0-12.7 K₂O 1.3-1.7 1.1-1.9 0.9-2.1 CaO 5.8-6.4 5.6-6.6 5.4-6.8 BaO3.5-4.5 3.3-4.7 3.1-4.9 B₂O₃ 16.4-16.8 16.2-17.0 16.0-17.2 Al₂O₃ 2.4-4.62.2-4.8 2.0-5.0 SiO₂ 42.4-45.6 42.0-46.0 41.8-46.2 TiO₂   0-1.2   0-1.4  0-1.6 ZrO₂ 3.4-5.9 3.2-6.1 3.0-6.3 NiO 2.6-2.8 2.4-3.0 2.2-3.2 CuO0.7-0.8 0.5-1.0 0.3-1.2 Fe₂O₃ 0.2-0.5 0.1-0.7 0.05-0.9  Co₂O₃ 0.8-1.00.6-1.2 0.4-1.4 MnO₂ 1.4-1.9 1.2-1.1 1.0-1.3

TABLE 11 Ground Coat Preferred Compositions Preferred PreferredPreferred Preferred Preferred Com- Com- Com- Com- Com- Com- ponentposition V position W position X position Y position Z Li₂O 3.14 3.143.14 3.14 2.93 Na₂O 11.43 11.43 11.43 11.43 12.23 K₂O 1.64 1.64 1.641.64 1.31 CaO 6.40 6.40 6.40 6.40 5.83 BaO 4.48 4.48 4.48 4.48 3.59 B₂O₃16.45 16.45 16.45 16.45 16.72 Al₂O₃ 3.10 4.50 3.10 3.10 2.48 SiO₂ 42.4442.44 42.44 45.50 44.49 TiO₂ 0.00 0.00 0.00 0.00 1.17 ZrO₂ 4.35 4.355.80 4.35 3.48 NiO 2.72 2.72 2.72 2.72 2.70 CuO 0.74 0.74 0.74 0.74 0.72Fe₂O₃ 0.29 0.29 0.29 0.29 0.47 Co₂O₃ 0.96 0.96 0.96 0.96 0.81 MnO₂ 1.841.84 1.84 1.84 1.47

TABLE 12 Additive Component Formulation Ranges Component Most PreferredPreferred Typical NO₂ 2.7-2.9 2.5-3.1 2.3-3.3 F 7.1-8.6 6.9-8.8 6.7-9.0

Methods

The enamel compositions according to the present invention can beapplied by any of the known wet application processes such as spraying,dipping, flow coating, and electrodeposition. Preferably, thecompositions are dried prior to firing when the compositions are appliedusing a wet application process. Drying is typically accomplished usingheating lamps. The drying time and temperature are not critical. Theapplication rate of the compositions by wet application processes willvary depending upon the desired thickness of the resulting fired enamelcover coat. For example, a fired enamel cover coat having a thickness ofabout 140 Φm can be obtained when the application rate of the wet enamelcomposition is about 400 g/m².

The enamel compositions can also be applied using conventional dryelectrostatic application processes. In such instances, anorganopolysiloxane is typically added to the compositions to facilitateelectrostatic application. The application rate of the compositions bydry electrostatic processes will vary widely according to the desiredthickness of the resultant enamel cover coat. Typical application ratesare from about 200 g/m² to about 600 g/m². In other terms, theorganopolysiloxane may be added to the pre-fired enamel composition ofthe invention in an amount of 0.01-1 wt %, preferably 0.02-0.5 wt %,more preferably 0.03-0.4 wt % and still more preferably 0.05-0.25 wt %.

The enamel compositions according to the present invention are typicallyfired at a temperature of from about 1420 to about 1600° F. (770° C. toabout 870° C.) for about 2 to about 8 minutes. More preferably, thecompositions are fired at a temperature of from about 800° C. to about850° C. for about 3 to about 6 minutes. The optimal firing conditionsare 820° C. for about 3.5 minutes. It will be appreciated that firingtimes and temperatures are not critical, and a range of firing schedulescould be used.

Upon firing, the enamel compositions according to the present inventionform an enamel cover coat from which baked-on foods can be removedwithout the need for pyrolysis or highly alkaline cleaners. The enamelcompositions according to the invention are particularly well-suited forapplication on the interior surfaces of oven cavities, dripping pans,cookware, and other articles that are exposed to the risk of baked-onfood soiling. The compositions are also expected to find wideapplication in microwave ovens. The fired enamel cover coats can beproduced in a wide range of colors, including bright colors such as blueand green, by varying the pigments included as mill additions.

Mill added oxide (i.e., pigments) can also be added, for example, acobalt chrome spinel black. This also reduces the L color value of thefired color. However, excessive added oxide results in spray problemswith the enamels of the invention, which are dry appliedelectrostatically.

Pigments may be included in the pre-fired composition of the inventionin an amount of 0.01-2 wt %, preferably 0.1-1.5 wt %, more preferably0.25-1.25 wt %, still more preferably 0.5-1 wt % and most preferablyabout 1 wt %.

The fired cover coat enamels according to the invention are scratchresistant, stain resistant, and maintain their easy-to-clean propertiesover many heating cycles. In addition, baked-on food can be easilyremoved from the fired cover coat enamels without the need for hightemperature heating cycles or highly alkaline chemical cleaners. Mostbaked-on foods can be removed from the fired enamel cover coats usingwarm water. In a particularly preferred cleaning technique, surfaces inaccordance with the invention having baked-on food residue are exposedto warm water vapor, such as having a temperature of at least 150° F.(66° C.), and most preferably steam having a temperature of about 212°F. (100° C.) for at least about 3 minutes, more preferably at leastabout 5 minutes, and more preferably at least about 10 minutes. Suchsurfaces can also be exposed to liquid water which is preferably warmand more preferably at the noted temperatures for the noted timeperiods. After such exposure, the food or food residue can be easilycleaned off the surface. As noted, the cleaning efforts do not requirethe use of harsh or caustic cleaning agents or exposure to much greatertemperatures such as associated with pyrolysis.

The ground coat compositions according to the present invention can beapplied by any of the known wet application processes such as spraying,dipping, flow coating, and electrodeposition. Preferably, thecompositions are dried prior to firing when the compositions are appliedusing a wet application process. Drying is typically accomplished usingforced convection or forced air. The drying time and temperature are notcritical. The application rate of the compositions by wet applicationprocesses will vary depending upon the desired thickness of theresulting fired enamel cover coat.

The ground coat compositions can also be applied using conventional dryelectrostatic application processes. In such instances, one or moreagents are typically added to the compositions to facilitateelectrostatic application. The application rate of the compositions bydry electrostatic processes will vary widely according to the desiredthickness of the resultant ground coat.

The ground coat compositions according to the present invention aretypically fired according to practices known in the art. It will beappreciated that firing times and temperatures are not critical, and arange of firing schedules could be used.

In accordance with the invention, multilayer coated substrates areprovided. In a preferred embodiment, a substrate receives a ground coatas described herein and then also receives an enamel cover coat asdescribed herein. The ground coat is preferably disposed between and incontact with the substrate and the enamel cover coat. However, it willbe appreciated that the invention includes a wide array of otherconfigurations.

When utilized in conjunction with one another, the ground coat and theenamel cover coat can be applied, dried, and fired in a variety ofdifferent strategies. For example, a ground coat and an enamel covercoat can be applied via a two-coat/two-fire dry process in which a dryground coat is applied and then fired, followed by application of a dryenamel cover coat to the fired ground coat. The enamel cover coat isthen fired. A two-coat/one-fire dry process can be used in which a dryground coat is applied and then a dry enamel cover coat is applied ontothe unfired ground coat. The two layers are then collectively fired.Another method involves a two-coat/two-fire wet/wet process in which awet ground coat is applied, dried, and then fired. A wet enamel covercoat is then applied onto the fired ground coat, dried, and then fired.Yet another process is referred to as a two-coat/one-fire wet/dryprocess involving application of a wet ground coat, drying and thenapplication of a dry enamel cover coat on the dried ground coat. Theresulting layers are then collectively fired. In still anothertechnique, referred to as a two-coat/one-fire wet/wet process, a wetground coat is applied followed by application of a wet enamel coat ontothe undried ground coat. A single firing is performed.

EXAMPLES Example 1 Two-Coat/Two-Fire Application

Glass frit according to the preferred composition C from Table 2 wasmilled into an electrostatic powder composition as shown in Table 7.This powder is designated as “Powder Enamel 1.”

TABLE 7 Powder Enamel 1 Powder Formulation Raw Material Powder Enamel 1Frit C 99.5 Spinel Black Oxide 1.0 Siloxane 0.18 Fineness 1-2%/200 MSieve Screening 100 mesh Post Milling Heat Treatment 200° F. (93° C.)for 18 hours

Powder Enamel 1 was applied to a steel substrate as follows. First, 33to 40 g/ft² (355 to 430 g/m²) of electrostatic ground coat was appliedover cleaned-only ASTM A424-compliant enameling grade steel.Electrostatic ground coats suitable for pyrolytic self-cleaning ovensare preferred, but any ground coat that creates adhesion on steel couldbe used. If a pyrolytic self-cleaning ground coat is used, such coatingis fired at about 1560° F. (850° C.) for 90 seconds at peak metaltemperature. The ground coat was allowed to cool, and Powder Enamel 1was applied at a coating density of about 34 to 40 g/ft² (366 to 430g/m²) and fired at about 1560° F. (850° C.) for 90 seconds at peak metaltemperature.

Test plates were prepared by a two-coat/two-fire dry electrostaticprocess. About 34 to 40 g/ft² (366 to 430 g/m²) of flecked bluepyrolytic ground coat were applied electrostatically to 5.5 inch by 5.5inch (14 cm by 14 cm) cleaned Type 1 enameling steel plates. The groundcoat was fired at 1560° F. (850° C.) for 4.0 minutes in the hot zone inan electric continuous furnace. Powder Enamel 1 was applied at a coatingdensity of 33 to 47 g/ft² (355 to 506 g/m²) and fired at 1560° F. (850°C.) for 4.0 minutes. Powder Enamel 1 fired out into a smooth glossy grayfinish free from defects. The Lab color measured on a DatacolorInternational Spectraflash SF450 color machine was L=25.7, a=−0.8, andb=−2.5. The dark gray color can be measured in other color spaces aswell. The CIELab color was L*=37.8, a*=0.8, and b*=−2.6.

It will be noted that although flecked blue pyrolytic ground coats wereprepared, in many applications it may be preferred to prepare and/orprovide a flecked gray pyrolytic ground coat.

Cleanability was tested against a reference standard self-cleaningpyrolytic standard, preferably the ground coat used for the water-cleanenamel.

Six foodstuffs to be tested were prepared as follows:

-   -   1. AHAM mixture    -   2. Cherry pie filling    -   3. Lemon juice    -   4. Beef gravy    -   5. Ketchup    -   6. Egg whites (or egg beaters)

The recipe for AHAM is shown in Table 8.

TABLE 8 AHAM Mixture Recipe AHAM Mixture U.S. Metric 75% Lean groundbeef 4 oz. 113 g Grated cheddar cheese ½ cup 119 mL Whole milk ½ cup 119mL Granulated white sugar ½ cup 119 mL Canned sour pie cherries ½ cup119 mL Dry, uncooked instant tapioca pudding mix 2 tbsp. 30 mL Large rawegg 1 1 All-purpose flour 2 tbsp. 30 mL Tomato juice ½ cup 119 mL

First, the panels were placed in a conventional free-standing electricrange that was then preheated to 450° F. (232° C.). Second, the oven wasturned off, and 0.5 teaspoon (2.5 ml) of each of the noted foodstuffswas applied to the panels. Next, the soils were baked-on at 450° F.(232° C.) for 1 hour.

The oven was allowed to cool for 15 minutes. A traditional pyrolyticenamel was soiled as a reference sample. To rate the cleanability of thecoatings, the soiled panels were placed in an enameled broiler pan. Tothe broiler pan was added 3 to 4 cups (700 to 1000 ml) of water. Thebroiler pan with water and the soiled panels were then heated in theoven at 250° F. (121° C.) for 30 minutes and allowed to cool for 30minutes.

Using a Scotch-Brite scouring sponge, it was first attempted to removeall the soils with a light rub. After evaluating and recording, theattempt was changed to a hard rub to finalize scoring. Each soilreceived a score according to the rating system shown in Table 9 setforth below.

TABLE 9 Rating System Per Soil Force and Residue Score Light Rub FullCleaning 5 Light Rub Some Residue 4 Hard Rub Full Cleaning 3 Hard RubSome Residue 2 Ingredients Can't Be Removed 1

The score for each soil was summed and the totals were assigned ratingsaccording to the criteria in Table 10.

TABLE 10 Cleanability Ratings Cleanability Score Class 25-30 A 20-24 B15-19 C 10-14 D 0-9 E

Using this testing method, Powder Enamel 1 exhibited the cleanabilitycharacteristics shown in Table 11.

TABLE 11 Cleanability of Powder Enamel 1 Applied With aTwo-Coat/Two-Fire Process Powder Soil Pyrolytic Enamel 1 AHAM 0 5 CherryPie Filling 0 4 Lemon Juice 5 5 Beef Gravy 1 5 Ketchup 1 4 Egg Whites orEgg Beaters 1 5 Total Score 8 28 Rating E A

As evident from the data in Table 11, a coating prepared from atwo-coat/two-fire application of Powder Enamel 1 exhibited significantlybetter cleanability characteristics as compared to a standardself-cleaning pyrolytic coating.

Example 2 Two-Coat/One-Fire Application

Test plates were prepared by a two-coat/one-fire dry electrostaticprocess. A base coat was applied at a coating density of about 5 toabout 7 g/ft² (54 to 75 g/m²) followed by an application of PowderEnamel 1 at a coating density of 33 to 47 g/ft² (355 to 506 g/m²). Testplates were fired at 1560° F. (850° C.) for 4.0 minutes.

The cleanability was tested using the procedure described in Example 1.The results are shown in Table 12.

TABLE 12 Cleanability of Powder Enamel 1 Applied With aTwo-Coat/One-Fire Process Powder Soil Pyrolytic Enamel 1 AHAM 0 5 CherryPie Filling 0 4 Lemon Juice 5 5 Beef Gravy 1 5 Ketchup 1 4 Egg Whites orEgg Beaters 1 5 Total Score 8 28 Rating E A

As evident from Table 12, a coating prepared from a two-coat/one-fireapplication of Powder Enamel 1 exhibited significantly bettercleanability characteristics as compared to the noted self-cleaningpyrolytic coating.

Example 3 Color

This is an example of a frit formulation for forming a blue version ofthe coating. Glass frit according to preferred composition E from Table2 was milled into electrostatic powder composition using the formulashown in Table 13. This powder is designated as “Powder Enamel 2.”

TABLE 13 Powder Enamel 2 Powder Formulation Raw Material Powder Enamel 2Frit E 99.5 Cobalt Aluminate Blue Oxide 0.25 Siloxane 0.18 Fineness1-2%/200 M Sieve Screening 100 mesh Post Milling Heat Treatment 200° F.(93° C.) for 18 hours

Test plates were prepared by a two-coat/two-fire dry electrostaticprocess. About 34 to 40 g/ft² (366 to 430 g/m²) of flecked bluepyrolytic ground coat were applied electrostatically to 5.5 inch by 5.5inch (14 cm by 14 cm) cleaned Type 1 enameling steel plates. The groundcoat was fired at 1560° F. (850° C.) for 4.0 minutes in the hot zone inan electric continuous furnace. Powder Enamel 2 was applied at a coatingdensity of 33 to 47 g/ft² (355 to 506 g/m²) and fired at 1560° F. (850°C.) for 4.0 minutes. Powder Enamel 2 fired out into a smooth glossy grayfinish free from defects.

The cleanability was tested using the procedure described in Example 1.The results are shown in Table 14.

TABLE 14 Cleanability of Powder Enamel 2 Applied With aTwo-Coat/Two-Fire Process Powder Soil Pyrolytic Enamel 2 AHAM 0 5 CherryPie Filling 0 4 Lemon Juice 5 5 Beef Gravy 1 5 Ketchup 1 4 Egg Whites orEgg Beaters 1 5 Total Score 8 28 Rating E A

As evident from the data in Table 14, a coating prepared from atwo-coat/two-fire application of Powder Enamel 2 exhibited significantlybetter cleanability characteristics as compared to a standardself-cleaning pyrolytic coating.

Example 4 Two-Coat/Two-Fire, Wet/Wet

Preferred glass composition C from Table 2 can also be ground withconventional additives known to the industry for wet spray, dip, or flowcoat application. Frit C was milled into a slurry according to theformula shown in Table 15 (values in parts by weight). This slurry isdesignated as Enamel 3. This is a recipe typically used for flow coatingor dipping enamels, and other combinations of enamel raw materials couldalso be used.

TABLE 15 Slurry Formulation Raw Material Slurry Enamel 3 Frit C 100Spinel Black Oxide 1 Ball Clay 4 Aluminum Oxide 4 Aluminum Phosphate 2Bentonite 0.45 Magnesium Carbonate 0.4 Potassium Carbonate 0.35 SodiumAluminate 0.031 Potassium Nitrite 0.15 Gum Arabic 0.01 Seqlene 0.018Water 47

The slurry was applied at a coating density of 33 to 47 g/ft² (355 to506 g/m²) to a previously wet-applied and fired ground coated steel andfired at 1560° F. (850° C.) for 4.0 minutes. The enamel slurry fired outinto a smooth glossy gray finish free from defects.

The cleanability of the resulting enamel coating was tested using theprocedure described in Example 1. Results are shown in Table 16.

TABLE 16 Cleanability of Enamel 3 Applied Wet With a Two-Coat/Two-FireProcess Soil Pyrolytic Enamel 3 AHAM 0 5 Cherry Pie Filling 0 3 LemonJuice 5 5 Beef Gravy 1 4 Ketchup 1 3 Egg Whites or Egg Beaters 1 5 TotalScore 8 25 Rating E A

As evident from the data in Table 16, a coating prepared from a wetversion of Enamel 3 exhibited significantly better cleanabilitycharacteristics as compared to a standard self-cleaning pyrolyticcoating.

Example 5 Two-Coat/One-Fire, Wet/Dry

A coated substrate could be formed by appropriately applying a wetground coat composition as described herein. The ground coat would thenbe subjected to a drying operation. After sufficient drying, a dryenamel composition is then applied onto the dried and un-fired groundcoat. The dry enamel composition can be applied in a variety ofdifferent fashions, including for example by powder coat techniques.After application of the enamel composition, the multilayer laminate isthen subjected to a firing operation to collectively fire the groundcoat and the enamel coat.

Example 6 Two-Coat/One-Fire, Wet/Wet

Using this method, a coated substrate could be formed by appropriatelyapplying a wet ground coat composition onto a substrate. Prior to dryingof the ground coat, a wet enamel composition is applied thereon. Theresulting layered assembly is then subjected to firing conditionswhereby the ground coat and the enamel coat are both collectively fired.

Many other benefits will no doubt become apparent from futureapplication and development of this technology.

All patents, published applications, and articles noted herein arehereby incorporated by reference in their entirety.

It will be understood that any one or more feature or component of oneembodiment described herein can be combined with one or more otherfeatures or components of another embodiment. Thus, the presentinvention includes any and all combinations of components or features ofthe embodiments described herein.

As described hereinabove, the present invention solves many problemsassociated with previous type compositions, methods, and coatings.However, it will be appreciated that various changes in the details,materials and arrangements, which have been herein described andillustrated in order to explain the nature of the invention, may be madeby those skilled in the art without departing from the principle andscope of the invention, as expressed in the appended claims.

What is claimed is:
 1. A composition adapted for forming an enamelcoating, the composition, comprising prior to firing: (i) a glasscomponent including: from about 7.1% to about 7.9% Na₂O, from about 7.0%to about 7.7% K₂O, from about 0.6% to about 1.0% ZnO, from about 2.7% toabout 3.3% BaO, from about 19.3% to about 20.7% Al₂O₃, from about 10.8%to about 11.8% SiO₂, from about 0.7% to about 1.2% TiO₂, from about14.4% to about 15.6% ZrO₂, from about 29.2% to about 31.3% P₂O₅, andfrom about 0.1% to about 5.2% Co₂O₃ and (ii) at least one additiveselected from the group consisting of fluorine and NO₂, and allpercentages are by weight.
 2. The composition of claim 1, wherein the atleast one additive is present, and prior to firing, is selected from thegroup consisting of 0.78-3 wt % fluorine and 1.5-4.71 wt % NO₂.
 3. Thecomposition of claim 2 wherein the enamel composition further includes:from about 0% to about 0.25% Ni, at least 0.75% pigment, and at least0.05% of at least one siloxane.
 4. The composition of claim 1, whereinthe enamel composition includes less than 0.20% Ni.
 5. The compositionof claim 1, wherein the enamel is devoid of nickel.
 6. A compositionhaving a Hunter L color value of less than 30 obtained by firing thecomposition of claim
 1. 7. An enamel coated substrate, the enamelcoating having a composition prior to firing that comprises: (i) a glasscomponent and (ii) an effective amount of at least one additive,selected from the group consisting of 0.78-3 wt % fluorine and 1.50-4.71wt % NO₂, wherein the glass component includes from about from about7.1% to about 7.9% Na₂O, from about 7.0% to about 7.7% K₂O, from about0.6% to about 1.0% ZnO, from about 2.7% to about 3.3% BaO, from about19.3% to about 20.7% Al₂O₃, from about 10.8% to about 11.8% SiO₂, fromabout 0.7% to about 1.2% TiO₂, from about 14.4% to about 15.6% ZrO₂,from about 29.2% to about 31.3% P₂O₅, and from about 0.1% to about 5.2%Co₂O₃, and all percentages are by weight.
 8. The enamel coated substrateof claim 7, wherein the at least one additive is selected from the groupconsisting of 0.88-2.6% fluorine and 2.0-4.61% NO₂.
 9. The enamel coatedsubstrate of claim 7 wherein the substrate is selected from the groupconsisting of steel and aluminum.
 10. The enamel coated substrate ofclaim 7 wherein the composition is disposed on a ground coat.
 11. Theenamel coated substrate of claim 10 wherein the ground coat is disposedon a substrate selected from the group consisting of steel and aluminum.12. A composition adapted for forming an enamel coating, thecomposition, comprising prior to firing: from about 2.5% to about 3.6%Li₂O, from about 11.0% to about 12.7% Na₂O, from about 0.9% to about2.1% K₂O, from about 5.4% to about 6.8% CaO, from about 3.1% to about4.9% BaO, from about 16.0% to about 17.2% B₂O₃, from about 2.0% to about5.0% Al₂O₃, from about 41.8% to about 46.2% SiO₂, from about 0% to about1.6% TiO₂, from about 3.0% to about 6.3% ZrO₂, from about 2.2% to about3.2% NiO, from about 0.3% to about 1.2% CuO, from about 0.05% to about0.9% Fe₂O₃, from about 0.4% to about 1.4% Co₂O₃, and from about 1.0% toabout 1.3% MnO₂, all percentages by weight.
 13. The composition of claim12, wherein TiO₂ is present in an amount of from about 0.7% to about1.2%.